Insulated concrete panel form and method of making same

ABSTRACT

An insulated concrete form panel system, and method of making same, is provided, the system and method comprising first and second opposed panels forming a cavity therebetween and an internal connector frame serving as a mold for receiving expandable polymer material to form the first and second panels, such that the irreleasably pre-assembled connector frame extends between, and is integral to, first and second panels. The present system provides first and second panel pairs may be mechanically connected to panel pairs positioned adjacent thereto (e.g. above, below, or side-by-side), increasing integrity of the structure.

CROSS REFERENCES

This application claims priority to U.S. Patent Application No.61/917,188 filed Dec. 17, 2013 entitled “Improved Insulated ConcretePanel Form and Method of Making Same”, incorporated herein in itsentirety.

TECHNICAL FIELD

The present disclosure relates to insulated concrete formwork (ICF) usedfor concrete construction. More specifically, the present disclosurerelates to an improved ICF pre-formed panel system and method of makingsame.

BACKGROUND

Concrete forms have long been used as formwork for the construction ofconcrete structures, such as the walls or floors of a building.Traditional form systems typically entail setting up two spaced apartform panels and pouring concrete into the space created between thepanels. After the concrete hardens, the forms are removed, leaving thecured concrete wall. Traditional systems, however, have severaldrawbacks including the time required to erect the forms, the time forthe concrete to cure, and the time to take down the forms, making theprocess expensive and labour-intensive.

Many modular insulated concrete form (ICF) systems are been developed toovercome the drawbacks of traditional form systems. Modular ICF systemstypically comprise setting up the form system, generally classified aseither “block” or “panel” systems, pouring the concrete into the spacebetween the forms and leaving the form in place. As such, the insulatingform becomes a permanent part of the structure after the concrete cures.Modular ICF systems are increasingly popular because they serve toinsulate the concrete structure in addition to containing the fluidconcrete as it solidifies, reducing the time and cost required to createthe structure.

“Block” ICF systems typically comprise preassembled blocks having twoexpanded polystyrene (EPS) foam members connected together with ties orwebs, wherein the ties or webs create a cavity between the two foammembers for receiving fluid concrete. The ties or webs connecting thepanels together can be molded to the foam members during themanufacturing process. As such, block ICF systems are often referred toas “fixed-tie” systems, and the blocks are installed at the constructionsite by stacking the blocks one on top of another (in a staggeredfashion similar to the assembly of a brick wall). Blocks are thenaffixed together by fastening the webs of one block to the webs of anadjacent block manually, often with cable-ties.

As a result the manufacturing process, however, the size, shape andcavity size of EPS blocks are limited by the molding machine used tocreate the block. Further, stacking multiple blocks one atop the othercreates a plurality of joints between the blocks, reducing the overallstrength of the wall, increasing the risk of vertical or horizontalskewing, and making the incorporation of design elements, such aswindows, doors, corners etc., difficult.

“Panel” ICF systems are often constructed to be longer (e.g. taller)than block systems for faster installation. A number of variations ofmodular panel ICF systems and methods for their use have been developed.Typically, such panel ICF systems use two opposed EPS foam panelsmanufactured from commercially available pre-formed expanded polystyreneslabs connected together with spacers to form a cavity for receivingconcrete between the two panels. The polystyrene slabs are cut down tosize using a hot-wire cutting process and the spacers connecting thepanels together are extruded to the desired size/shape from plasticmaterials before being affixed to the panels. The spacers are eitherfastened to the interior surface of the panels, or extend through thepanels themselves, to create the cavity therebetween. Spacers or“bridging members” are known to have varying shapes, sizes, andstrengths, often being used to reinforce the building structure.

Panel ICF systems allow for the manufacture of larger panels, resultingin easier and faster installation at the construction site. The panelscan also be stacked one on top of the other (many stories high) to formthe concrete structure. Larger panels also reduce the number of jointsbetween panels and the risk of the wall skewing, increasing the overallstrength of the wall. Design elements, such as doors and corners, arealso easier to incorporate in panel structures. Although the prior artproposes variations to achieve improvements with concrete form systems,however, many drawbacks still exist.

By way of example, Canadian Patent Application No. 2,597,832 describes apanel ICF system where two panels are connected together by individualinternal spacers coupled to individual external studs protruding throughthe panel and held together by external support straps. Both panels arepre-formed and cut from an EPS slab to the desired panel size and shape,including the apertures through the panels for receiving the internalspacers/external studs. At the construction site, the worker must firstline the two panels up then manually position each individual spacerinto the apertures of both panels. This laborious process requires thatcutting of the panels be extremely precise to achieve proper alignmentof the spacers/studs and apertures for receiving same.

A similar system is described in U.S. patent application Ser. No.12/200,846, however the individual spacers are mounted on a commonspacer “frame” (extending vertically up the interior surface of thepanel). Use of the spacer frame provides simpler installation thanhaving to align a plurality of individual spacers. Although somewhateasier to install, the panel system nonetheless requires detailedpositioning and cutting of the pre-formed panels and the aperturestherethrough for receiving the internal spacer “frame” and correspondingstuds. The system is also held together by external connector straps.

Despite the benefits provided by known panel ICF systems, themanufacturing process of cutting panels from standard EPS creates wasteof excess material and must be accurate (e.g. placement of apertures forreceiving spacers, and positioning of spacers with correspondingexternal stud and strapping) for on-site assembly of the panel structureto be efficient and successful. One further disadvantage common to theprior art is the limited ability to readily vary the spacing between theside panels of the forms, and therefore the thickness of the concretewall.

There is a need for an improved ICF panel system and a process of makingsame, the system being capable of being manufactured into one continuoussection for easy installation in the structure. It is desired that sucha system could provide an internal stabilizing frame for use as a moldto receive expandable polystyrene material, such that the frame becomesintegral to the panels molded thereto. Such a system may provide foreasy assembly of pre-formed panels at the construction site, without thepanels being limited in size or shape.

SUMMARY

There is provided an improved insulated concrete form panel systemcomprising two opposed form panels positioned in spaced relation tocreate a cavity therebetween, and an internal skeletal frame positionedwithin the cavity, wherein the frame is pre-assembled and serves as amold for receiving expanded polystyrene material to form the opposedpanels. According to embodiments herein, the internal frame comprises aplurality of bridge members irreleasably connected to a plurality ofstud members, such that the bridges are positioned substantiallyperpendicular to the studs. The internal frame is integrally connectedto the opposed form panels molded thereto, and provides that each panelpair section can be mechanically connected to adjacent panel pairsection via both the bridge members connecting to adjacent bridgemembers, and via the stud members connecting to stud members positionedthereabove or below. It is understood that any reference to horizontal,vertical, above or below are for explanatory purposes only and are notintended to be limiting.

More specifically, an insulated concrete form panel system is provided,the system comprising first and second panels having exterior andinterior surfaces and positioned in opposed spaced relation forming acavity between the interior surfaces, an internal connector framedisposed within the cavity having a plurality of bridge membersirreleasably connected to a plurality of stud members, each bridgemember having a first end and a second end, each first and second endhaving connection means for connecting adjacent bridge memberspositioned end-to-end, and a plurality of side ends, each side endhaving opposed first coupling means for coupling the bridge members tothe stud members, and each stud member having a first end, a second end,each first and second end having connection means for connectingadjacent stud members positioned end-to-end, and at least one secondcoupling means corresponding to the first coupling means for couplingthe bridge members to the stud members, wherein the stud members areintegral to first and second panel members. It is understood that thefirst and second panels are irreleasably connected to one another viainternal frame, and that adjacent first and second panel pairs areslidably connected to one another via mechanical (“friction” or“interference fit”), increasing the integrity of the structure. A methodof manufacturing the insulated concrete form panel system is alsoprovided.

A method of manufacturing an insulated concrete form panel system isalso provided, the panel system having first and second panels inopposed spaced relation forming a cavity therebetween for receivingliquid concrete, the method comprising:

-   -   a. providing assembly means for assembling a mold frame having        at least one bridge member irreleasably connected to at least        one stud member, the bridge and stud members positioned        substantially perpendicularly to each other to form a skeletal        matrix,    -   b. applying an expandable polymer material for forming the first        and second panels to the connector frame,    -   c. allowing the polymer material to solidify.

An apparatus of manufacturing the present insulated concrete form systemis also provided. The apparatus may or may not be entirely automated.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective side view of one panel pair of the presentsystem according to embodiments herein,

FIG. 2A shows a perspective side view of the bridge element according toembodiments herein,

FIG. 2B shows a top down view of the bridge in FIG. 2A,

FIG. 3A shows a perspective side view of the stud elements according toembodiments herein,

FIG. 3B shows a side view of the stud in FIG. 3A,

FIG. 4 shows a zoomed in view of the engagement (e.g. “snap-fit”)between the bridge and stud elements according to one embodiment herein,

FIG. 5 shows a side view of bridge member having grooves for receivingreinforcing steel according to embodiments herein,

FIG. 6 shows a perspective view of a panel form according to embodimentsherein being installed in a wall structure,

FIG. 7 shows a side view of the panel form in FIG. 6 being slidablyreceived by an adjacent panel form in the wall structure,

FIG. 8 shows a side perspective view of an apparatus for forming thepresent panel system according to embodiments herein, and

FIG. 9 shows a top down view of the apparatus in FIG. 8.

DESCRIPTION OF EMBODIMENTS

The present insulated concrete form system and method of making samerelate to the fabrication of concrete walls, foundations, floors, andother concrete structures. Apparatus and methodologies more particularlydescribed herein are intended as illustrative only since numerousmodifications and variations therein will be apparent to those skilledin the art.

According to embodiments herein, the present insulated concrete form(ICF) system 10 comprises first and second panels 12,14, each panelhaving interior surfaces 12 i,14 i, and exterior surfaces 12 e,14 e,respectively. Having regard to FIG. 1, in position, first and secondpanels 12,14 are in opposed spaced relation such that their interiorsurfaces 12 i,14 i form a space or cavity 16 therebetween. Duringinstallation, concrete is poured in its fluid state into cavity 16 andallowed to cure (i.e., harden) to form the structure. The type andvolume of concrete received within cavity 16 is determined by cavity 16,that is—by the distance between surfaces 12 i,14 i and height of panels12,14.

Panels 12,14 can be manufactured from any appropriate lightweight foammaterial including an expandable polymer material such as expandedpolystyrene (“EPS”). The polymer material may be in particulate or beadform, provide desired thermal insulation and sufficient strength (Rfactor, high density, etc.) to hold the concrete. The polymer materialmay further provide impedance to sound transmission.

According to embodiments herein, panels 12,14 can be manufactured tohave any desired pre-determined width, length and height according tothe particular structure being built. Panels 12,14 may each have astandard width or thickness of approximately 3-3¼ inches, and having astandard length (e.g., side to side, or horizontal to the ground) ofapproximately 12-48 inches, and any height (e.g., extendinglongitudinally) that may be desired including a standard height of atleast 4 feet. A person skilled in the art would appreciate that thesize, shape and dimensions of panels 12,14 can be altered according tothe particular structure being built. It is further understood that thepanels 12,14 may be installed vertically or horizontally (for e.g. in afoundation setting below-grade), and that any reference to the “width”,“height” or “length” of panels 12,14 is for explanatory purposes onlyand is not intended to limit the scope of the present invention.

Panels 12,14 are connected to one another by internal connector skeleton“matrix” or frame 18. Connector frame 18 comprises horizontal bridgemember 20 and vertical stud member 22. Bridge 20 and stud 22 couple toform a skeletal connector frame 18 of the present structure, the frame18 being pre-assembled to serve as a mold for the application of theexpandable polymer material to form panel 12,14. It is understood thatthe number of bridge members 20 and studs 22 positioned in frame 18 candictate the overall size (e.g. height and length) of panels 12,14.

FIGS. 2A and 2B show one embodiment of bridge member 20 having a firstend and a second end. First and second end of bridge member 20 may haveconnection means 20 a,20 b for mechanically (e.g., slidably) engagingbridge members 20 positioned adjacent to one another (e.g. end-to-end)in skeletal frame 18. Each connection means 20 a,20 b means may formcorresponding apertures 23 a,23 b, respectively, for securing adjacentbridge members 20 together by interference or “friction” fit. Forexample, during installation, the first end of bridge members 20 of afirst wall section is slidably received by the second end of bridgemembers 20 of a second adjacent wall section being placed into position.More specifically, female connection means 20 b of the first bridgemembers 20 slidably receive male connection means 20 a of the second,adjacent bridge members 20. Once in sliding engagement, apertures 23a,23 b align and a bolt or other securing member (not shown) may bepositioned through both apertures 23 a,23 b, further securing thestructure. A person skilled in the art would appreciate that apertures23 a,23 b or any other connecting means may be used to secure bridgemembers 20 positioned in end-to-end alignment. Bridge members 20 mayfurther comprise stabilizing bar 27 for guiding bridge members 20together and further stabilizing bridge members 20.

FIGS. 2A and 2B also show bridge member 20 having at least one side end,each side end having opposed couplings for irreleasably connectingbridge 20 to studs 22. For example, side ends may have a coupling means24 for coupling bridge member 20 to stud 22. Coupling means 24 maycomprise female “snap-fit” engagement means for receiving correspondingsecond coupling means 26 of stud 22. It is understood that at least onebridge member 20 may be positioned perpendicularly to a plurality ofstuds 22 to form skeletal frame 18. In some embodiments, bridge members20 may be positioned to extend laterally (horizontally) along interiorsurfaces 12 i,14 i of panels 12,14, although reference to the horizontaland vertical are not limiting. Side ends may further comprise grooves orrecesses 25 (FIG. 5) for receiving reinforcing steel, such as re-bar,prior to concrete being poured into cavity 16. It is understood that thereinforcing steel may be utilized to provide further structuralintegrity to the concrete.

FIGS. 3A and 3B show one embodiment of stud member 22 having a first(e.g., upper) end and a second (e.g., lower) end. First and second endsof stud 22 may have connection means 22 a,22 b for slidably engagingother studs 22 positioned adjacent thereto (e.g. above and below) inframe 18. For example, during installation, first connection means 22 aof studs 22 in a first wall section may comprise a female end 22 a forslidably receiving the corresponding male end 22 b of studs 22 in asecond wall structure being positioned above the first wall section. Inembodiments herein, studs 22 may be positioned to extend longitudinally(e.g., vertically) along interior surfaces 12 i,14 i of panels 12,14,although reference to the horizontal and vertical are not limiting. Morethan one stud 22 may be aligned prior to forming panels 12,14,increasing the length (height) of the panels 12,14 as desired.

FIGS. 3A and 3B also show stud member 22 having at least one couplingmeans 26, said coupling means 26 positioned in spaced longitudinalrelation along stud 22, for irreleasably connecting studs 22 to bridgemembers 20. Coupling means 26 may comprise male “snap-fit” engagementmeans, as shown in FIG. 4, for being received by corresponding couplingmeans 24 of bridge members 20. It is understood that a plurality ofstuds 22 may be coupled to at least one bridge member 20 to formskeletal frame 18. Reference to horizontal and vertical are forexplanation purposes only.

As depicted in FIGS. 6 and 7, it is understood that first and secondpanels 12,14 are irreleasably connected to one another via internalframe 18, and that, during installation, adjacent first and second panel12,14 pairs can be mechanically fastened to one another (eliminating theneed to “tie” the panels together), increasing structure stability, buteasily disengaged if errors, concept changes or damage to panels 12,14occur. Mechanical engagement between first and second panel 12,14 pairsincreases the integrity and strength of the structure, reduces time andexpertise required to assemble the structure, and aligns of the panels12,14 of the overall structure (i.e. pulling adjacent panel pairstogether and minimizing skewing between pairs). The mechanicalconnection can also be sufficiently sufficient to prevent any skewingbetween the wall and the concrete footing (upon which the present system10 is installed) by pulling the panels into alignment.

It is contemplated that the present insulated concrete form system 10may be configured to create form panels 12,14 via manual or automatedmeans, or a combination thereof. For example, FIGS. 8 and 9 depictapparatus 50 for manufacturing panels 12,14 according to embodimentsherein. It is understood that apparatus 50 may be used to pre-assembleskeletal frame 18 according to the size of panels 12,14 beingmanufactured, to apply expandable material to the frame 18 (e.g.,allowing the material to mold around, or to, studs 22 of the frame 18),to allow the material to cure to form panels 12,14 integral to frame 18and, once cured, to cut the panels 12,14 to size. Apparatus 50 may beentirely automated.

It is contemplated that panels 12,14 can be molded to pre-assembledframe 18 to form one solid, continuous section of the structure,creating more accurate panel 12,14 tolerances, minimizing on-siteadjustment, and reducing worker error (e.g. “gaps” created by hot-wirecutting mechanisms). Molding panels 12,14 directly to the pre-assembledframe 18 enables the present system 10 to be entirely pre-formed anddelivered to the job site for easy installation, saving time, costs andthe necessity of having skilled workers.

It is understood that the present apparatus and method of making samemay result in a substantial reduction in manufacturing and assembly timeand costs because the present apparatus may be pre-assembled andpre-molded prior to delivery to the job site, wherein the panels 12,14pairs need only be mechanically connected together in position (besideeach other or one atop the other) at the job site. It is furthercontemplated that the present insulated concrete form system 10 may beused to manufacture custom panel systems, such as corners, angles orwindows. The present insulated concrete form system 10 may also becustom designed to be incorporated into or used with pre-existing blockor panel ICF systems.

Example 1

It is understood that the width, height and length of the presentinsulated concrete form system can be dictated by the size of thestructure being built.

By way of example, the present form system may be configured such thatindividual bridge members may have a width (between side ends)corresponding to standard building sizes (i.e. to create a cavity ofbetween approximately two feet and four feet). Individual bridge members20 may further be configured to extend to standard building lengths, orto form panels approximately 4″, 6″ or 8″ long. It is understood,however, that a plurality of bridge members 20 can be aligned end-to-endto create substantially longer panels 12,14.

The present form system may further be configured such that studs 22 mayhave a height corresponding to standard building construction (i.e. atleast four, eight or twelve feet tall). It is understood that aplurality of stud members 22 may be aligned end to end to createsubstantially taller panels 12,14.

The present form system may further be configured to create shaped ornon-linear (e.g. curved) panels 12,14. Panels 12,14 may also be adaptedfor use with known or customized “corner” members, as would beappreciated by a person skilled in the art.

It is contemplated that the present form system may be manufacturedmanually (e.g. assembling frame 18, foaming and cutting the panels 12,14by hand), automatically by a apparatus 50, or a combination thereof.Where automated, the present system may be entirely continuous, creatinga single panel unit that can be easily installed at the constructionsite.

It is an advantage of the present form system that, when positioned inplace, panels 12,14 connect to panels 12,14 positioned beside, above orbelow to increase the integrity and strength of the structure, to reducethe time and expertise required to install panels 12,14, particularly inhigher structures, and to serve to align the panel forms creating theoverall structure (i.e. minimizing skewing caused by the wall or floorof the structure).

It should be known and understood that the present disclosure provides adetailed description of various elements required to build a panelsystem used in constructing a concrete structure, but that many otherknown elements required to finish the structure have not describedherein.

Although a few embodiments have been shown and described, it will beappreciated by those skilled in the art that various changes andmodifications can be made to these embodiments without changing ordeparting from their scope, intent or functionality. The terms andexpressions used in the preceding specification have been used herein asterms of description and not of limitation, and there is no intention inthe use of such terms and expressions of excluding equivalents of thefeatures shown and described or portions thereof, it being recognizedthat the invention is defined and limited only by the claims thatfollow.

We claim:
 1. An insulated concrete form panel, comprising: first andsecond panels having exterior and interior surfaces and positioned inopposed spaced relation forming a cavity between the interior surfaces,an internal connector frame disposed within the cavity having aplurality of bridge members irreleasably connected to a plurality ofstud members, each bridge member having a first end and a second end,each first and second end having connection means for connectingadjacent bridge members positioned end-to-end, and a plurality of sideends, each side end having opposed first coupling means for coupling thebridge members to the stud members, and each stud member having a firstend, a second end, each first and second end having connection means forconnecting adjacent stud members positioned end-to-end, and at least onesecond coupling means corresponding to the first coupling means forcoupling the bridge members to the stud members, wherein the studmembers are integral to first and second panel members.
 2. The panel ofclaim 1, wherein the bridge members extend substantially perpendicularlyto the stud members.
 3. The panel of claim 1, wherein the first andsecond panels are formed from an expandable polymer material.
 4. Thepanel of claim 3, wherein the expandable polymer material is expandedpolystyrene.
 5. The panel of claim 3, wherein the connector frame ispre-assembled to serve as a mold for the polymer material.
 6. The panelof claim 1, wherein the first and second panels have any pre-determinedwidth, height and length.
 7. The panel of claim 5, wherein the first andsecond panels are molded to have a width of approximately 3-3¼ inches.8. The panel of claim 5, wherein the first and second panels have alength of approximately 12 to 48 inches.
 9. The panel of claim 5,wherein the first and second panels have a height of at least 4 feet.10. The panel of claim 1, wherein the bridge member further comprises atleast one stabilizing bar.
 11. The panel of claim 1, wherein a firstform panel can mechanically engage an adjacent second form panelpositioned beside, above or below the first form panel.
 12. A method ofmanufacturing an insulated concrete form panel, the panel having firstand second panels in opposed spaced relation forming a cavitytherebetween for receiving concrete, the method comprising: a. providingassembly means for assembling a mold frame having at least one bridgemember irreleasably connected to at least one stud member, the bridgeand stud members positioned substantially perpendicularly to each otherto form a skeletal matrix, b. applying an expandable polymer materialfor forming the first and second panels to the connector frame, c.allowing the polymer material to solidify.
 13. The method of claim 12,wherein the method may be manual, automatic or a combination thereof.14. An apparatus for manufacturing the insulated concrete form ofclaim
 1. 15. The apparatus of claim 14, wherein the apparatus may beautomated.